User manual MITSUBISHI ENGINE 4G9 SERVICE MANUAL

[. . . ] 37 ENGINE <4G6> - General Information/Service Specifications 11A-3 GENERAL INFORMATION Items Total displacement mL Bore ´ Stroke mm Compression ratio Combustion chamber Camshaft arrangement Number of valve Intake Exhaust Valve timing Intake Opening Closing Exhaust Opening Closing Fuel system Rocker arm Auto-lash adjuster 4G64-GDI 2, 350 86. 5 ´ 100. 0 11. 5 Pentroof + ball-in-piston DOHC 8 8 BTDC 16_ ABDC 60_ BBDC 56_ ATDC 16_ Electronically controlled multipoint fuel injection Roller type Equipped SERVICE SPECIFICATIONS Items Alternator drive belt tension Vibration frequency Hz When checked When a used belt is installed When a new belt is installed Tension N When checked When a used belt is installed When a new belt is installed Deflection (Reference value) mm When checked When a used belt is installed When a new belt is installed Standard value 189 - 232 201 - 222 241 - 276 392 - 588 441 - 539 637 - 833 6. 7 - 9. 0 7. 2 - 8. 4 5. 0 - 6. 4 Limit - 11A-4 Items Power steering oil pump and A/C compressor drive belt tension ENGINE <4G6> - Service Specifications/Sealants Standard value Vibration frequency Hz When checked When a used belt is installed When a new belt is installed Tension N When checked When a used belt is installed When a new belt is installed Deflection (Reference value) mm When checked When a used belt is installed When a new belt is installed 108 - 132 114 - 126 137 - 157 392 - 588 441 - 539 637 - 834 11. 7 - 15. 3 12. 5 - 14. 3 8. 8 - 11. 0 5_ BTDC ± 3_ Approx. 20_BTDC*1 M/T A/T 600 ± 100*2 650 ± 100 0. 5 or less 100 or less 1, 570 - 300 Within 1 2. 5 3. 8 - 4. 5 Limit 1, 210 - 300 Max. 56*3 99. 4 - Basic ignition timing Ignition timing Idle speed r/min CO contents % HC contents ppm Compression pressure kPa - r/min Compression pressure difference of all cylinder kPa Intake manifold vacuum kPa Cylinder head bolt shank length mm Auto-tensioner push rod movement mm Timing belt tension torque Nm (Reference value) Auto-tensioner rod protrusion amount mm NOTE *1: Indicates the value measured within 4 minutes since the engine was started. *3: Indicates the value when more than 4 minutes have passed since the engine was started. SEALANTS Items Beam camshaft cap Cylinder head Cam position sensor support Oil pan Flywheel or drive plate bolt Specified sealants 3M ATD Part No. 8660 or equivalent MITSUBISHI GENUINE MD970389 or equivalent PART Remarks Semi-drying sealant - 3M Stud Locking 4170 or equivalent ENGINE <4G6> - Special Tools 11A-5 SPECIAL TOOLS Tool Number MB991502 Name MUT-II sub assembly Use D D D D Measuring the drive belt tension Checking the ignition timing Checking the idle speed Erasing diagnosis code MB991668 Belt tension meter set Measuring the drive belt tension (used together with the MUT-II) MB990767 End yoke holder D D Holding the camshaft sprocket Holding the crankshaft sprocket MD998719 MD998754 or Crankshaft pulley holder pin D D Holding the camshaft sprocket Holding the crankshaft sprocket MD998713 Camshaft oil seal installer Press-in of the camshaft oil seal MD998727 Oil pan remover Removal of oil pan MD998781 Flywheel stopper Securing the flywheel MD998776 Crankshaft rear oil seal installer Press-in of the crankshaft rear oil seal MB990938 Handle Press-in of the crankshaft rear oil seal 11A-6 Tool ENGINE <4G6> - Special Tools/On-vehicle Service Number MD998382 Name Crankshaft front oil seal installer Use Installation of crankshaft front oil seal MD998285 Crankshaft front oil seal guide MD998767 Tension pulley socket wrench Timing belt tension adjustment GENERAL SERVICE TOOL MZ203827 Engine lifter Supporting the engine assembly during removal and installation of the transmission MB991453 Engine hanger assembly ON-VEHICLE SERVICE DRIVE BELT TENSION CHECK AND ADJUSTMENT ALTERNATOR DRIVE BELT TENSION CHECK Check the drive belt tension in the following procedure. [. . . ] NOTE Place the removed power steering oil pump in a place where it will not be a hindrance when removing and installing the engine assembly, and tie it with a cord. MZ203827 MB991453 AC" ENGINE MOUNT BRACKET REMOVAL 1. Remove the special tool which was attached when the transmission assembly was removed. Place a garage jack against the engine oil pan with a piece of wood in between, jack up the engine so that the weight of the engine is no longer being applied to the engine mount bracket, and then remove the engine mount bracket. AD" ENGINE ASSEMBLY REMOVAL After checking that all cables, hoses and harness connectors, etc. , are disconnected from the engine, lower the chain block slowly to remove the engine assembly downward from the engine compartment. ENGINE <4G6> - Engine Assembly INSTALLATION SERVICE POINTS 11A-39 "AA ENGINE ASSEMBLY INSTALLATION Install the engine assembly, checking that the cables, hoses, and harness connectors are not clamped. Engine side Arrow "BA ENGINE MOUNT STOPPER INSTALLATION Clamp the engine mount stopper so that the arrow points in the direction as shown in the diagram. Engine mount stopper Engine mount bracket "CA ENGINE MOUNT BRACKET INSTALLATION 1. Place a garage jack against the engine oil pan with a piece of wood in between, and install the engine mount bracket while adjusting the position of the engine. Remove the chain block and support the engine assembly with the special tool. NOTES 11B-1 ENGINE <4G9> CONTENTS GENERAL INFORMATION . 33 11B-2 ENGINE <4G9> - General Information/Service Specifications GENERAL INFORMATION Items Total displacement mL Bore ´ Stroke mm Compression ratio Combustion chamber Camshaft arrangement Number of valve Intake Exhaust Valve timing Intake Opening Closing Exhaust Opening Closing Fuel system Rocker arm Auto-lash adjuster 4G93 1, 834 81. 0 ´ 89. 0 12. 5 Pentroof + ball-in-piston DOHC 8 8 BTDC 15_ ABDC 56_ BBDC 55_ ATDC 15_ Electronically controlled multipoint fuel injection Roller type Equipped SERVICE SPECIFICATIONS Items Alternator drive belt tension Vibration frequency Hz When checked When a used belt is installed When a new belt is installed Tension N When checked When a used belt is installed When a new belt is installed Deflection (Reference value) mm When checked When a used belt is installed When a new belt is installed Standard value 143 - 185 155 - 175 203 - 234 294 - 490 343 - 441 588 - 784 9. 7 - 12. 9 10. 5 - 12. 0 6. 7 - 8. 5 Limit - ENGINE <4G9> - Service Specifications Items Power steering oil pump and A/C compressor drive belt tension Vibration frequency Hz When checked When a used belt is installed When a new belt is installed Tension N When checked When a used belt is installed When a new belt is installed Deflection (Reference value) mm Basic ignition timing Ignition timing Idle speed r/min M/T A/T CO contents % HC contents ppm Compression pressure kPa - r/min Compression pressure difference of all cylinder kPa Intake manifold vacuum kPa Cylinder head bolt shank length mm Timing belt tension torque Nm (Reference value) Auto-tensioner rod protrusion amount mm When checked When a used belt is installed When a new belt is installed Standard value 114 - 139 121 - 133 145 - 166 392 - 588 441 - 539 637 - 833 10. 0 - 12. 0 10. 0 - 11. 0 7. 0 - 9. 0 5_ BTDC ± 3_ Approx. 6_BTDC)*2 600 ± 100*1 (750 ± 100)*2 650 ± 100 (750 ± 100)*2 0. 5 or less 100 or less 1, 790 - 300 2. 5 - 4. 0 3. 8 - 4. 5 Limit - 11B-3 1, 400 - 300 Max. 37 99. 4 - NOTE *1: Varies depending on the transmission oil temperature. *2: Indicates the value when more than 4 minutes have passed since the engine was started. 11B-4 SEALANTS Items Beam camshaft cap Cylinder head Cam position sensor support Oil pan Flywheel or drive plate bolt ENGINE <4G9> - Sealants/Special Tools Specified sealants 3M ATD Part No. 8660 or equivalent MITSUBISHI GENUINE MD970389 or equivalent PART Remarks Semi-drying sealant - 3M Stud Locking 4170 or equivalent SPECIAL TOOLS Tool Number MB991502 Name MUT-II sub assembly Use D D D D Measuring the drive belt tension Checking the ignition timing Checking the idle speed Erasing diagnosis code MB991668 Belt tension meter set Measuring the drive belt tension (used together with the MUT-II) MB990767 End yoke holder D D Holding the camshaft sprocket Holding the crankshaft sprocket MD998719 MD998754 or Crankshaft pulley holder pin MD998713 Camshaft oil seal installer Press-in of the camshaft oil seal MD998781 Flywheel stopper Securing the flywheel <M/T> or drive plate <A/T> ENGINE <4G9> - Special Tools Tool Number MD998776 Name Crankshaft rear oil seal installer Use 11B-5 Press-in of the crankshaft rear oil seal MB990938 Handle MD998717 Crankshaft front oil seal installer Press-in of the crankshaft front oil seal MD998767 Tension pulley socket wrench Timing belt tension adjustment GENERAL SERVICE TOOL MZ203827 Engine lifter Supporting the engine assembly during removal and installation of the transmission MB991453 Engine hanger assembly 11B-6 ENGINE <4G9> - On-vehicle Service ON-VEHICLE SERVICE DRIVE BELT TENSION CHECK AND ADJUSTMENT ALTERNATOR DRIVE BELT TENSION CHECK Check the drive belt tension by the following procedure. 15_ 15_ MB991668 (Microphone) 10 - 20 mm Tap lightly with a finger. Alternator pulley Crankshaft pulley <When using the MUT-II> 1. Turn the ignition switch to ON and select "Belt Tension Measurement" from the menu screen. Hold the microphone to the middle of the drive belt between the pulleys (at the place indicated by the arrow), about 10 - 20 mm away from the rear surface of the belt and so that it is perpendicular to the belt (within an angle of ± 15_). Gently tap the middle of the belt between the pulleys (the place indicated by the arrow) with your finger as shown in the illustration, and check that the vibration frequency of the belt is within the standard value. Caution (1) The temperature of the surface of the belt should be as close as possible to normal temperature. (2) Do not let any contaminants such as water or oil get onto the microphone. (3) If strong gusts of wind blow against the microphone or if there are any loud sources of noise nearby, the values measured by the microphone may not correspond to actual values. (4) If the microphone is touching the belt while the measurement is being made, the values measured by the microphone may not correspond to actual values. (5) Do not take the measurement while the vehicle's engine is running. Belt tension gauge Crankshaft pulley <When using a tension gauge> Use a belt tension gauge to check that the belt tension is within the standard value. Alternator pulley ENGINE <4G9> - On-vehicle Service Deflection 98 N Crankshaft pulley 11B-7 <Belt deflection check> Apply 98 N of force to the middle of the drive belt between the pulleys (at the place indicated by the arrow) and check that the amount of deflection is within the standard value. Standard value: Vibration frequency Hz Tension N Deflection (Reference value) mm 143 - 185 294 - 490 9. 7 - 12. 9 Alternator pulley Adjusting bolt Lock bolt ALTERNATOR DRIVE BELT TENSION ADJUSTMENT 1. Use the adjusting bolt to adjust the belt tension and belt deflection to the standard values. Standard value: Items When a used belt is installed 343 - 441 10. 5 - 12. 0 When a new belt is installed 203 - 234 588 - 784 6. 7 - 8. 5 Pivot bolt Vibration frequency Hz 155 - 175 Tension N Deflection (Reference value) mm NOTE Refer to P. 11B-6 concerning the measurement procedure of the alternator drive belt tension. [. . . ] Lift the tensioner pulley in the direction of the arrow and tighten the tensioner pulley bolt. Adjust the timing belt tension. Fixing bolt MD998767 Pin hole Tensioner pulley "CA TIMING BELT TENSION ADJUSTMENT 1. After turning the crankshaft a 1/4 turn anti-clockwise, turn it clockwise to the position where the timing marks are aligned. Loosen the fixing bolt of the tensioner pulley and using the special tool and a torque wrench, apply tension to the timing belt; then tighten the fixing bolt at the specified torque. [. . . ]